Composition for making coated expanded polystyrene foam



July 22, 1969 R. A. NONWEILER 3,451,205

COMPOSITION FOR MAKING COATED EXPANDED POLYSTYRENE FOAM Original Filed Nov. 6, 1964 FIG. 2 FIG. 3

INVENTOR. P/CHAED ,4. NO/VWE/LER United States Patent us. (:1. 2602.5 6 Claims ABSTRACT OF THE DISCLOSURE A rotational molding composition is provided for the production in a movable mold of an improved expandable polystyrene foam having a relatively thick integral protective coating that is formed simultaneously with the process of molding the expandable polystyrene beads. The composition comprises expandable polystyrene beads, a non-expandable thermoplastic resin powder, and a hydrate containing at least 25% by weight chemically bound water.

This invention relates to improvements in coated expanded polystyrene foam.

This application is a division of application Ser. No. 409,545, filed Nov. 6, 1964, now US. Patent No. 3,309,- 439, which was a continuation-in-part of my abandoned application Ser. No. 331,802, filed Dec. 19, 1963.

Heretofore, various types of articles have been made by the molding of expandable polystyrene beads, usually by first pre-expanding the beads, then charging the preexpanded beads into a mold, and then subjecting the mold to heat to cause further expansion and fusion of the beads in the mold. Polystyrene foam articles are used widely in packaging where strength consistent with lightness is desired, where insulation qualities are important, or where buoyancy is a desired characteristic.

The main drawbacks of present commercial foamed polystyrenes are their susceptability to denting or scratching and their limited resistance to attack by solvents or heat. It has heretofore been attempted to subsequently apply a coating, either in the form of an emulsion or a solvent, to the outside of the foamed article. The application of such coatings, however, involves a separate process and increases the expense of production, Furthermore, the coatings are necessarily quite thin. It has also been attempted to surface heat the finished article to melt down the surface for a predetermined distance inwardly and thus form a coating. This technique limits the surface coating to polystyrene, which has limited resistance to solvents and heat.

Another known coating method is that described by Jacob Frank in US. Patent No. 2,950,505. The Frank method involves depositing a non-expandable thermoplastic resin on the walls of a heated mold, filling the interior of the mold with expandable particles, and heating the mold to form fused articles having an integral skin. This method is obviously cumbersome and involves high labor costs.

I have discovered a novel molding composition that can be used directly to provide an improved expanded polystyrene foam having a relatively thick integral protective coating that is formed simultaneously with the process of molding the expandable polystyrene beads.

In accordance with the invention there is provided a free-flowing molding composition comprising expandable polystyrene beads, 0.33-3 parts by weight, per part beads, of a non-expandable thermoplastic resin powder and 3-40 percent by weight, based on the weight of the beads of retained Water in the form of a hydrate containing at least 25 percent by weight chemically bound water. Molded expanded articles having an integral skin are made by charging the molding composition into a casting mold having heat conducting walls and moving'the mold in a source of heat to cause movement of the denser non-expandable thermoplastic resin to a position against the mold walls and fusion thereagainst in the form of an external coating, while the less dense expandable polystyrene beads remain in the interior of the mold cross-section. The chemically bound moisture of the uniformly distributed hydrate is released to create steam throughout the mold cavity and to aid in transferring heat to the beads to cause expansion and fusion to each other and to the non-expandable resinous skin.

In the accompanying drawing illustrating a preferred embodiment of the invention in which the same reference numerals designate the same parts in all of the views:

FIG. 1 is a partially diagrammatic vertical sectional view through a molding oven illustrating one method of supporting the molds for multi-directional rotation while they are being heated;

FIG, 2 is a cross-sectional view through a mold with the partially completed coated and expanded article therein; and

FIG. 3 is an enlarged cross-sectional view of a wall of a completed article.

The ingredients of the composition can be blended in any desired manner. It is sometimes convenient to form a premix of the non-expandable synthetic thermoplastic resin and the hydrate and thereafter blend in the expandable polystyrene beads.

Expandable polystyrene is commercially available in bead or pellet form in sizes ranging between 10 and mesh, conveniently 20-40 mesh (U.S. Sieves). The beads or pellets are rendered expandable by the incorporation therein of a volatile organic blowing agent having a boiling point at atmospheric pressure ranging between about l0 and C. The particles that have attained the widest commercial acceptance contain a normally liquid aliphatic hydrocarbon blowing agent, such as pentane, petroleum ether, hexane, and the like, and are made by the process described in US. Patent No. 2,983,692 of Gaetano F. DAlelio. The polystyrene particles are preferably used in unexpanded condition. Although discrete partially expanded beads made by a pre-expansion step, such as described in Rodman, U. S. Patent No. 3,023,175, are operable as an ingredient in the molding composition, pre-expansion is not necessary or particularly desirable. The novel molding process works better with unexpanded beads and the cost of the pre-expansion, together with the equipment cost, is eliminated.

The non-expandable resin is used in powdered form, the individual particles being 10-325 mesh, preferably 20100 mesh (U.S. Sieves) in size. Thus, useful nonexpandable thermoplastic resins include polyethylene; polyethylene copolymers, such as ethylene-ethyl acrylate copolymers and ethylene-vinyl acetate copolymers; highmelting micro waxes; vinyl plastisols; polyvinyl chloride; polyvinyl acetates; copolymers of vinyl acetate and vinyl chloride; cellulose acetate; cellulose acetate butyrate; cellulose acetate propynate; polystyrene; copolymers of styrene and such monomers as butadiene, apha-methylstyrene, isobu-tylene and acrylonitrile; phenol-aldehyde, resorcinol-aldehyde and urea aldehyde resins; polyamides, polyacrylates, such as polymethylmethacrylate; polyurethanes; polycarbonates; and the like.

In formulating the novel molding composition, the polystyrene beads are blended with 0.33-3 parts by weight, per part beads, of the non-expandable thermoplastic resin powder. If less than 0.33 part by weight non-expandable resin powder is used, the resulting molded article has an insufficient thermoplastic skin surface. If more than three parts by weight non-expandable resin is used, the product has an insufficient expanded polystyrene core and the coating becomes unnecessarily thick. Best results are obtained using 0.67l.5 parts by weight, per part beads, of the non-expandable resin powder.

In addition to the expandable polystyrene and non-expandable thermoplastic resin, the molding composition of the invention must contain retained water in an amount ranging between about 3 and 40 percent by weight, based on the weight of the beads, in the form of a hydrate. The hydrate serves to distribute moisture uniformly through out the plastic mix while the mix retains the generic characteristics of a substantially dry, free-flowing powder. To be effective, the hydrate must contain at least 25 percent by weight chemically bound water and may, in the case of certain organic gels, contain up to 90 percent by weight bound water. Unbound water cannot effectively be uniformly distributed and is not retained by the composition for a useful period of time. The use of hydrates containing less than 25 percent bound water results in poor molding and a finished article having insufficient skin surface with poor foam polystyrene fusion. As noted above, the hydrate must be present in an amount sulficient to provide a retained water content ranging between about 3 and 40 percent by weight. If less than 3 percent Water in the form of a hydrate is used, the fusion is poor and the skin surface of the molded article is often insufficient. If more than 40 percent by weight water in the form of a hydrate is used, the free-flowing quality of the product is adversely affected. Best results are obtained using a hydrate in an amount sufficient to provide l5 percent by weight, based on the weight of the beads, of bound water. The following hydrates are especially useful in making the molding compositions of the invention, the number given in parentheses representing the amount of chemically bound water present in the particular hydrate: sodium-potassium tartrate (25% cupric sulfate (36%), ferrous sulfate (45%), aluminum ammonium sulfate (47%), sodium tetraborate (47%), magnesium sulfate (51%), sodium sulfate (55%), trisodium phosphate (56%), sodium silicate (60%), sodium carbonate (63%), hydroxyethyl cellulose gel (ca. 90%), methyl cellulose gel (ca. 90%), carboxymethyl cellulose gel (ca. 90%), and the like.

Often, the use of hydrates containing relatively large amounts of chemically bound water (ca. greater than 50%) causes the molding composition to become excessively damp and thus is detrimental to the necessary freefiowing characteristics. This is particularly true when such materials as sodium silicate and the organic gels are used as the hydrate. To offset the dampening effect of excessive amounts of bound water in the formulation, there can be optionally added a small quantity; i. e., up to 20 percent by weight, based on the weight of the beads, of an inert drying substance. The particular drying material selected varies with the choice of hydrate. For instance, with the inorganic hydrates, such as sodium or potassium silicate, excellent results are obtained using baking soda (sodium bicarbonate). If the organic cellulosic gels are used as the hydrate, highly absorbent inert substances, such as dehydrated or treated calcium carbonate or diatomaceous earth, are particularly effective. These materials are also useful in combination with inorganic hydrates. The specific quantity of inert drying material used varies with the amount of hydrate present and the amount of chemically bound water present in the particular hydrate. Generally, up to 10 percent drying material is sufficient to offset the excess amount of bound water and provide a substantially dry free-flowing molding composition. It the amount of drying material required is in the range of 10-20 percent, there is a slight tendency of the material to leach out through the skin of the molded article, which is detrimental to the physical appearance of the article. The use of more than 20 percent drying material is undesirable because of excessive leaching.

To produce colored articles according to the invention, there may be optionally added from 0.2-2 percent by weight, based on the Weight of the beads, of an organic or inorganic pigment. Other inert materials, such as vermiculite and powdered metals, may be added to produce unusual skin effects.

In the process of the invention, the molding composition is charged into a suitable mold, such as the molds 10 of FIGURES 1 and 2. These molds may be of any desired shape, depending upon the article to be molded, but are free of undercuts and are formed of suitable metal having good heat conducting qualities. Suitable mold materials are cast aluminum, electro-formed copper and nickel, formed sheet steel, or formed sheet aluminum. As an example, a steel mold as shown in FIG. 1, having an outside wall of 12 gauge steel and an inner wall of 16 gauge steel, would work well in a temperature of 550 F., with 5 /2 minutes molding time with the apparatus rotated at 8 rpm. on the horizontal axis and 2 rpm. on the other axis.

Molds for use in the invention are of the imperforate type and thus differ from the ordinary perforate or vented closed molds used for molding expandable polystyrene. Vents or perforations are unnecessary because the introduction of steam or gases is unnecessary; the steam required for heat distribution is generated from within the composition by the release of bound water from the hydrate, and, in effect, is introduced into the mold before it is closed. In any case, the non-expandable thermoplastic resin fuses against the external walls at an early stage of the molding operation and thereafter prevents the escape of gases from the interior of the mold cavity. Furthermore, perforations in the mold are undesirable, because they become plugged with non-expandable resin, cause irregularities in the skin of the molded product, and interfere with discharge of the molded article from the mold.

lhe molds may be in two parts, separable along a parting line 11, to permit charging of the mix therein. Covering of a predetermined portion of the depth of the cavity 12 of the lower mold section is usually ample for an article of the type shown in FIG. 2. After the molds have been charged and closed, they are suitably secured to the racks 13 of a suitable casting machine. In carrying out the present method, it is important that the molds be moved sufficiently to cause the desired action to take place while the molds are being subjected to the action of heat. This is best accomplished by a rotational casting machine or by a centrifugal casting machine. One such machine is illustrated in FIG. 1, wherein the racks 13 are suitably mounted for rotation around the axis of the studs 14 and also around the axis of the shaft 15. Thus, the apparatus provides for rotation in two planes at right angles to each other. In the apparatus of FIG. 1 the shaft 15 may be suitably driven to act through the bevel gear 16 meshing with bevel gear 17 to cause rotation of the mold-holding racks 13 in opposite directions around the axis of the studs 14. At the same time, the arrangement is such that the racks are also rotating around the axis of the shaft 15. One such mechanism is disclosed in the Delacoste Patent No. 2,624,072, and other apparatus for imparting a suitable motion is disclosed in Bailey Patent No. 2,824,986 and Miller Patent No. 2,784,454. An example of a centrifugal casting machine is shown in Bola Patent No. 2,811,747.

The apparatus of FIG. 1 shows the mold rotating mechanism operable within a chamber 18 having a suitable door 19, there being suitable means within the chamber for subjecting the molds to heat. In one method, hot air from a suitable source may be admitted, preferably under pressure, at 20 to charge the container 18 with heated air and thereby cause heating of the molds as they are being rotated, there being an outlet 21 for the heating medium. The rotational casting is performed at a temperature of between 225 and 750 F., preferably between 300 and 600 F.

As the molds are rotated, the denser non-expandable thermoplastic material, such as the polyethylene, together with a suitable pigment if one is being used, absorbs heat at a faster rate and gravitates to the outside against the wall of the mold, as shown at 22, FIG. 2, while the expanding polystyrene beads, being less dense, stay in between as at 23. In addition, the ,unexpandable thermoplastic resin, which preferably has a lower melting point, fuses at a relatively early stage of the process against the external walls, as at 22, with the still expanding beads in the interior, as at 23. At a later stage, the polystyrene beads fuse together between the external coatings 22. Due to the fact that the molding composition contains a hydrate, such as water-glass or borax, the bound moisture therein is released and turns to steam within the mold cavity'to transfer heat uniformly to the expanding beads, the steam flowing in between all of the beads to distribute the heat effectively throughout the latter. As the beads expand, they become insulators, but the steam that has been generated in the mold cavity from the water-glass, or the like, continues to transmit heat uniformly to the beads while they are expanding. The molding is continued until the expansion of the beads has been continued for a sufficient length of time to create a satisfactory foamed wall and to fuse the skin to the surface of the foam. This period of time for molding may be anywhere between two and fifteen minutes, depending upon the wall thick ness of the product, the source of'heat, and the nature of the mold section. The temperature within the chamber 18 may vary within the range of 225-750 F., depending upon wall thickness, desired handling time and other factors.

The density of the finished product can be controlled by the relative amount of expandable polystyrene beads in the molding composition charged into the mold. The density may be anywhere between two pounds per cubic foot and 20 pounds per cubic foot. The density of the final product may also be varied by changing the type of non-expandable thermoplastic resin used in the preparation of the molding composition.

After the molding has been completed, the door 19 of the chamber 18 may be opened and the molds removed, whereupon the molds are separated to remove the cast products, such as the open-topped container 24 shown in FIG. 2. It will be found that in the finished product, of which a section is shown in FIG. 3, all of the fusedtogether foamed beads will occupy the interior as at 25 (FIG. 3) and there will be integral exterior coatings 22, either plain or colored, depending upon whether or not pigment is added to the formulation. This coating will be formed of the non-expandable thermoplastic material of the molding composition and will provide excellent surface integrity. It will minimize the possibility of denting or scratching, and such coatings are resistent to heat and to certain solvents which might attack an uncoated polystyrene foam article.

The molded articles are very desirable for use in picnic chests, ice pails, and other insulated containers, and in marine items such as fishnet fioats, ring buoys, or other articles where floatation qualities are desired.

Various changes and modifications may be made without departing from the spirit of the invention, and all of such changes are contemplated as may come within the scope of the claims.

My invention is further illustrated by the following examples:

EXAMPLE I A molding composition was prepared by blending 125 g. of expandable polystyrene beads, ranging in size between 16 and 40 mesh (U.S. Sieves) and containing 5.3

percent by weight pentane as a blowing agent, g. of a polyethylene homopolymer powder having a mesh size of from 30-200 mesh, 12 percent by weight water, based on the weight of the beads, in the form of sodium silicate (60 percent chemically bound water), and 6.6 percent by weight, based on the weight of the beads, of sodium bicarbonate.

The composition was charged to a rotational molding machine having a single-cavity, cast aluminum mold. The mold was manually operated, closed and inserted into the molding machine and thereafter into the water immersion cooling tank. The mold had a 7 inch inner wall thickness and a inch outer wall thickness. Molding was done at a six minute contact time at an air temperature of 590 F. and a rotation of 9 /2 rpm. The molded article was completely submerged in the cooling water for one minute and twenty seconds. The resulting product was a container 12" x 6%" x 3%" with a inch wall thickness. The molded container had a uniform skin surface and excellent fusion of the expanded polystyrene beads both to each other and to the polyethylene skin.

EXAMPLE II The procedure of Example I was repeated with the exception that the molding composition consisted of only expandable polystyrene beads and polyethylene powder. The composition was a dry, free-flowing powder, but it gave a poor molding with a poor foam polystyrene fusion. The addition of free water to the composition gave an acceptable immediate molding, but it lacked the excellent fusion of the product of Example I. Delayed molding was poor with poor foam polystyrene fusion.

- EXAMPLES 'III-XII A series of moldings were made according to the procedure of Example 1 to determine the effectiveness of hydrates containing varying amounts of chemically bound water. In each formulation there was used 125 g. of expandable polystyrene and 125 g. of polyethylene powder.

The results are shown in the following table.

TABLE I Example No. Formulation Results III Beads plus polyethylene Dry, free-flowing powder;

plus 12% water in the poor molding with insufform of calcium sulfate fieient skin surface and (CaSOi-ZIIQO) containing poor foamed polystyrene 21% chemically bound fusion. water.

IV Beads plus polyethylene Dry, free-flowing powder;

plus 12% water in the excellent molding with form of sodium-potassium uniform skin surface. tartrate (N aK C4H405- Slight leaching of salt to 41120) containing 25% the skin surface. chemically bound Water.

V Beads plus polyethylene Dry, free-flowing powder;

plus 12% water in the good molding with uniform of cupric sulfate form skin surface, slightly (OuS O4-5I I2O) containing less foamed polystyrene 36% chemically bound fusion than Ex. I. Marked water. blue coloration of surface.

VI Beads plus polyethylene Dry, free-flowing powder;

plus 12% water in the good molding with uniform of ferrous sulfate form skin surface, slightly (FeSOi-HEIZO) containing less foamed polystyrene 45% chemically bound fusion than Ex. I. Slight water. leaching of salt to the skin surface. Marked reddishbrown coloration of the surface.

VII Beads plus polyethylene Dry, free-flowing powder;

plus 12% water in the fair molding with uniform form of aluminum skin surface but fair ammonium sulfate foamed polystyrene [A12(S O-|)3- (NI-I4) 2S04- fusion.

24 2Q], containing 47% chemically bound water.

VIII Beads plus polyethylene Dry, free-flowing powder;

plus 12% water in the excellent molding with uniform skin surface, excellent fusion.

Dry, free-flowing powder;

excellent molding with uniform skin surface.-

TABLE I-Continued the relative proportions of polystyrene beads and polyethylene powder were varied as indicated below.

in a SUMO mixture. XXVII Beads plus polyethylene in a 80/20 mixture.

Dry, free-flowing powder; excellent foamed poly- Example No. Formulation Results X Beads plus polyethylene Dry, free-flowing powder;

plus 12% water in the good molding with uniform of sodium sulfate form skin surface, slightly (Nags 04-10112 0) conless foamed polystyrene taining 55% chemically fusion than Ex. I. bound water. XI Beads plus polyethylene Do.

plus 12% water in the form of sodium phosphate (NB PO -12Hz0) contaming 56% chemically bound water. XII Beads plus polyethylene Do.

plus 12% water in the form of sodium carbonate (N e20 03-10H2O) containing 63% chemically 15 bound water.

The results of Table I show that the hydrate must contain at least 25 percent by weight chemically bound water.

EXAMPLES XIII-XXIII A series of moldings were made to determine the amount of retained water that must be furnished by the hydrate in the molding composition. In each formulation there was used 125 g. of expandable polystyrene and 125 g. of polyethylene powder. The results are shown in the following table.

TABLE II Example Not Formulation Results XIII Beads plus polyethylene Dry, free-flowing powder;

plus 24% water in the excellent molding with form of sodium borate uniform skin surface. (borex) excellent fusion. XIV Beads plus polyethylene Do.

plus 6% water in the form of sodium boi'ate (borax). XV Beads plus polyethylene De. plus 3% water in the form of sodium borate (borax). XVI Beads plus polyethylene Dry, free-flowing powder; 40

plus 2% water in the poor molding with uniform of sodium silicate. form skin surface, but poor foamed polystyrene fusion. XVII Beads plus polyethylene Dry, free-flowing powder;

plus 4% water in the marginal melding with form of sodium silicate. uniform skin surface. 5

Fair foamed polystyrene fusion. XVIII Beads plus polyethylene Damp, free-flowing powder;

plus 8% water in the good molding with uniform of sodium silicate. form skin surface, slightly less foamed polystyrene v fusion than Ex. I. XIX Beads plus polyethylene Same as Ex. I except damp,

plus 12% water in the free-flowing powder and form of sodium silicate. slight leaching of salt to the skin surface. XX Beads plus polyethylene Damp, non-free-fiowing plus 18% water in the powder until sodium biform of sodium silicate carbonate addition then plus 9.9% sodium bidry, free-flowing. Good carbonate. molding with uniform skin surface. Very slight leaching of salt to the skin B a l l n l s it XX t XXI ea s p us p0 ye 1y one time as x. excep plus 24% water in the slight leaching of salt to form of sodium silicate the skin surface. plus 13.2% sodium bicarbonate. XXII Beads plus polyethylene Do.

plus 36% water in the form of sodium silicate plus 19.8% sodium bicarbonate. XXIII Bends plus polyethylene Same as Example XX plus 42% water in the except excessive leaching form of sodium silicate of salt to the skin surface. plus 23.1% sodium bicarbonate.

It is seen from the above examples that at least 3 percent and not more than 40 percent retained water is required to produce a good molded article.

EXAMPLES XXlV-XXVII The procedure of Example I was repeated, except that styrene but poor molding and insufiicient polyethylene skin surface.

It is seen from the above examples that more than 0.25 and less than 4 weight'parts resin per part beads must be present in the mix.

EXAMPLE XXVIII The procedure of Example I was repeated using varying air temperatures of 25 0, 7 00 and 750 F. At the lower temperatures, there was obtained good to excellent moldings with a uniform skin surface. At 750 F., there was some distortion of the foam polystyrene.

EXAMPLES XXIX-XXXII Excellent molded articles were made according to the procedure of Example I from compositions formed by blending polystyrene beads in the relative amounts indicated below withla premix formed by blending the thermoplastic resin, the hydrate, drying agent and coloring pigment as desired. i

I XXIX 40 parts pre-mix (77.7 parts ethylene-ethyl/acrylate copolymer; 15.5 parts water glass (60% retained water); 5.2 parts baking soda; 0.8 parts water; 0.8 parts yellow coloring pigment).

60 parts expandable polystyrene beads between 10 and mesh (US. Sieves).

XXX

40 parts pro-mix (88 parts vinyl acetate copolymer of polyethylene; 10 parts water combined with 2 parts carboxymethyl cellulose) 60 parts yellow colored expandable beads.

' XXXI 40 parts pro-mix (9 parts vinylacetate/polyethylene copolymer; 75 parts cellulose acetate butyrate powder; 10 parts watercombined with 2 parts hydroxyethyl cellnlose; 1 part red coloring pigment; 3 parts calcium carbonate filler).

60 parts expandable beads.

XXXII 50 parts pre-mix (80 parts crystal polystyrene powder; 15 parts water glass (60% retained water); 5 parts baking soda).

50 parts expandable polystyrene beads.

clients which are separable during molding as a result of motion comprising a physical admixture of:

expandable polystyrene beads containing a volatile organic blowing agent,

0.33-3 parts by weight, per part beads, of a non-expandable thermoplastic resin powder, and

3-40 percent by weight, based on the weight of beads,

of retained water in the form of a hydrate containing at least 25 percent by weight chemically bound water.

2. A free-flowing molding composition as claimed in claim 1 which is dry and in which the amount of nonexpandable thermoplastic resin powder is 0.6 71.5 parts by weight, per part beads, and in which the amount of retained water in the form of a hydrate is 1015 percent, based on the weight of beads, with said hydrate containing 25-90 percent by weight of chemically bound water.

3. A composition according to claim 2 wherein the free-flowing quality of the composition is maintained by the addition of up to 10 percent by weight, based on the weight of beads, of an inert drying substance.

4. A free-flowing molding composition as claimed in claim 1 which is dry and in which the amount of nonexpandable thermoplastic resin powder is 0.67-1.5 parts by weight, per part beads, and in which the amount of retained water in the form of a hydrate is 10-15 percent, based on the weight of the beads, and is in the form of hydrated sodium silicate.

5. A free-flowing molding composition as claimed in claim 4 which also contains up to 10 percent, based on the weight of beads, of sodium bicarbonate.

6. A free-flowing molding composition as claimed in claim 2 in which the non-expandable thermoplastic resin powder is ethylene polymer, and in which the retained water is in the form of hydrated sodium tetraborate.

References Cited MURRAY TILLMAN, Primary Examiner M. FOELAK, Assistant Examiner US. Cl. X.R. 

